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Upcycling plastic waste into syngas by staged chemical looping gasification with modified Fe-based oxygen carriers

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  • Wu, Shijie
  • Ren, Zongqiang
  • Hu, Qiang
  • Yao, Dingding
  • Yang, Haiping

Abstract

A novel staged approach, termed staged chemical looping gasification (SCLG) was proposed in this work, for the efficient upcycling of plastic waste into H2-rich syngas with exceptional carbon conversion reaching up to 99%. In such staged system, plastic was firstly pyrolyzed to generate hydrocarbon volatiles, followed by chemical looping reforming in the presence of oxygen carriers, and steam and air was also feed in sequence for carbon removal, syngas regulation and lattice oxygen recovery. A series of Fe-M-Al oxygen carriers (OCs, where M represents Mg, Ca, Mn, Mo, La, Ce) were synthesized and employed for SCLG of waste disposable masks. The performance and stability of these OCs were thoroughly investigated and compared in terms of H2 content and syngas production, while the physicochemical properties characterized by various techniques such as N2 isothermal adsorption-desorption, FESEM, XRD, TPO, and H2-TPR. Results showed that compared with the controlled FeAl sample, all the six modified OCs exhibited higher activity towards syngas production, due to the simultaneously enhanced both partial oxidation reactions and thermal decomposition reactions during the proposed SCLG process. However, the modifiers displayed different role for promoting gasification. Specifically, the addition of Ca significantly promoted the thermal cracking of plastic pyrolysis volatiles and lead to the deep extraction of carbon and H2, whereas the deposited carbon was further gasified into syngas in steam stage. As a result, Fe-Ca-Al showed the highest syngas yield and carbon conversion of 177.89 mmol/gOC and 99.03%, respectively. Fe-Mg-Al possessed relatively high CO selectivity, with the CO/(CO + CO2) ratio of 90.40%. The presence of MoO3 made the Fe-Mo-Al equipped with strong oxygen supply ability, leading to high content of oxygen-containing gases. Furthermore, the cycle stability of OCs was also conducted. The slight decrease in activity of Fe-Ca-Al was due to the metal sintering, whereas Fe-Mo-Al presented relatively stable syngas yield. The proposed staged chemical looping gasification with modified FeAl was demonstrated as a promising upcycling utilization of disposal plastic waste.

Suggested Citation

  • Wu, Shijie & Ren, Zongqiang & Hu, Qiang & Yao, Dingding & Yang, Haiping, 2024. "Upcycling plastic waste into syngas by staged chemical looping gasification with modified Fe-based oxygen carriers," Applied Energy, Elsevier, vol. 353(PB).
    • Handle: RePEc:eee:appene:v:353:y:2024:i:pb:s0306261923014691
    DOI: 10.1016/j.apenergy.2023.122105
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    1. Sun, Zhao & Chen, Shiyi & Hu, Jun & Chen, Aimin & Rony, Asif Hasan & Russell, Christopher K. & Xiang, Wenguo & Fan, Maohong & Darby Dyar, M. & Dklute, Elizabeth C., 2018. "Ca2Fe2O5: A promising oxygen carrier for CO/CH4 conversion and almost-pure H2 production with inherent CO2 capture over a two-step chemical looping hydrogen generation process," Applied Energy, Elsevier, vol. 211(C), pages 431-442.
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    1. Zhang, Xueqi & Yip, Alex C.K. & Rosas, Santiago & Nusheh, Mohammad & Pang, Shusheng, 2025. "Enhanced redox performance of cement-modified Fe-based oxygen carrier during biomass chemical looping gasification," Energy, Elsevier, vol. 320(C).
    2. Fang, Shiwen & Zheng, Xiongwei & Lin, Yan & Ding, Luzhou & Yan, Shuchang & Li, Jun & Huang, Zhen & Huang, Hongyu, 2024. "Evaluation of the chemical looping gasification characteristics of kitchen waste using CuFe2O4 and NiFe2O4 as oxygen carriers," Energy, Elsevier, vol. 312(C).
    3. Divine Senanu Ametefe & George Dzorgbenya Ametefe & Dah John & Abdulmalik Adozuka Aliu & Macaulay M. Owen & Solehuddin Shuib & Aisha Hamid, 2025. "Energy Generation from Plastic Composites: A Systematic Review of Sustainable Practices and Technologies," Circular Economy and Sustainability, Springer, vol. 5(2), pages 1307-1343, April.
    4. Liang, Shuang & Liao, Yanfen & Zhang, Tongyu & Yang, Hailong & Wang, Tingwei, 2024. "Mechanism of lattice oxygen migration in decarburized Fe-based oxygen carriers to chemical looping gasification," Renewable Energy, Elsevier, vol. 236(C).
    5. Fu, Wenming & Cheng, Yoke Wang & Xu, Dequan & Zhang, Yaning & Wang, Chi-Hwa, 2024. "Reaction synergy of bimetallic catalysts on ZSM-5 support in tailoring plastic pyrolysis for hydrogen and value-added product production," Applied Energy, Elsevier, vol. 372(C).
    6. Zou, Jiecheng & Zhao, Lanxun & Hu, Qiang & Yao, Dingding & Yang, Haiping, 2024. "Pyrolysis and catalytic reforming of disposable plastic waste for syngas production with adjustable H2/CO ratio," Applied Energy, Elsevier, vol. 362(C).

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